Bubble mailer chill pack envelope

Abstract

An inner thermal container, molded from an expanded polystyrene, seals in temperature sensitive materials with a cooling means for maintaining a low temperature. Inner and outer coatings provide additional thermal, vapor, and moisture insulation. The inner thermal container is inserted and sealed in a bubble wrap mailer envelope with layers of vapor and moisture proof thermal insulation.

1 . A temperature insulated shock resistant mailer system comprising in combination: 
 an outer bubble wrap mailer envelope comprising a top and a bottom sheet each of bubble wrap material generally heat sealed together around the periphery of the two sheets and having at least one peripheral envelope opening therein and a means for sealing the envelope opening closed, the top and bottom sheets of bubble wrap providing a shock resistant cushion for contents of the bubble wrap mailer envelope as well as thermal insulation for the contents;    a temperature insulating moisture barrier and puncture barrier on at least one surface of both sheets of the outer bubble wrap mailer envelope so that the top and bottom sheets are water resistant and provided with further thermal insulation and puncture resistance;    an inner thermal container removably insertable within the outer bubble wrap mailer envelope, the inner container comprising a shell of light weight expanded polystyrene, the inner thermal container having an interior chamber for containing a temperature sensitive material and a means for maintaining the temperature sensitive material at a cold temperature within the interior chamber, a thermal insulation coating covering all wall surfaces of the interior chamber to enhance temperature retention, a vapor barrier and thermal insulation covering an exterior surface of the inner thermal container, a means for accessing the interior chamber to install and remove the contents, and means for sealing the inner thermal container closed to maintain the temperature sensitive material at a cold temperature, the inner thermal container and outer bubble wrap envelope together forming a temperature insulated, puncture resistant, and shock resistant mailer system for transporting a temperature sensitive material maintained at a cold temperature and protected from shock during transporting.    
   
   
       2 . The system of  claim 1  wherein the temperature insulating moisture and puncture barrier on at least one surface of both sheets of the outer bubble wrap mailer envelope comprises a layer of PERLITE.  
   
   
       3 . The system of  claim 2  further comprising a layer of aluminum MYLAR over the layer of PERLITE locking the layer of PERLITE in place.  
   
   
       4 . The system of  claim 1  wherein the thermal insulation coating covering all surface walls of the interior chamber of the inner thermal container comprises a layer of PERLITE.  
   
   
       5 . The system of  claim 4  further comprising a layer of aluminum MYLAR over the layer of PERLITE locking the layer of PERLITE in place.  
   
   
       6 . The system of  claim 1  wherein the temperature insulating moisture and puncture barrier on at least one surface of both sheets of the outer bubble wrap mailer envelope comprises a metalized foil laminated onto a strong co-extruded film.  
   
   
       7 . The system of  claim 1  further comprising an outer coating of MYLAR around the inner thermal container shell to provide a vapor barrier and to enhance temperature retention within the inner thermal container.  
   
   
       8 . The system of  claim 1  wherein the vapor barrier and thermal insulation covering an exterior surface of the inner thermal container comprises a layer of PERLITE to enhance temperature retention within the inner thermal container.  
   
   
       9 . The system of  claim 8  further comprising a layer of aluminum MYLAR over the layer of PERLITE locking the layer of PERLITE in place.  
   
   
       10 . The system of  claim 1  wherein the vapor barrier and thermal insulation covering an exterior surface of the inner thermal container comprises metallic foil laminated thereon.  
   
   
       11 . The system of  claim 1  wherein the vapor barrier and thermal insulation covering an exterior surface of the inner thermal container comprises a coating of reflective polyester.  
   
   
       12 . The system of  claim 1  wherein the inner thermal container comprises a pair of mating shells of molded light weight expanded polystyrene, at least one of the pair of mating shells having a recessed interior to retain the temperature sensitive material and the means for maintaining the temperature sensitive material at a cold temperature within the recessed interior, and the means for sealing the inner thermal container closed to maintain the temperature sensitive material at a cold temperature comprises mating overlapping peripheral edges forming an air tight seal between the pair of mating shells and an adhesive sealing tape adhered to and covering the mating peripheral edges of the pair of mating shells to maintain the mating overlapping peripheral edges in a sealed condition during transportation.  
   
   
       13 . The system of  claim 1  wherein the means for sealing the envelope opening closed comprises an end flap folded over the envelope opening, the end flap having an adhesive surface to seal the end flap closed over the envelope, the adhesive surface normally covered by a peel-off strip which is removed to adhere the end flap.  
   
   
       14 . The system of  claim 1  wherein the means for maintaining the temperature sensitive material at a cold temperature within the interior chamber comprises a gel ice pack comprising specially formulated, non-toxic, non-caustic refrigerants hermetically sealed in a heavy-duty and puncture-proof pouch which is re-usable by re-freezing for each use.